Method of weaving pile fabrics



Nov;A 10, 1936. F. M. KAUFMAN METHOD 0F wEAvING PILE FABRICS Filed April 12, 193s Patented Nov.- j10, 1936 UNITED srlirlazsA PATENT vFFICE METHOD oF WEAVING PILE FABRICS Frank M. Kaufman, Merion, Pa., assigner to Collins & Aikman Corporation, Philadelphia, Pa., a corporation of Delaware Application April 12, 193s, serial No. 665,724 forium. (ci. 13esem l use, by face wefts, and other of the pile warps are interlaced with the ground wefts and cut so as to form cut pile having the form of a W or .so-called fast pile weave.

Such fabrics are woven double, in accordance l5 with my invention, upon a-loom having sets of pile loop gauges, such as wires or' cords extending warpwise of the loom, one set of gauges regulating and aiding in the formation of the uncut loops of the top fabric and another set of gauges regulating andy aiding in the. formation of the set of uncut loops of the bottom fabric. The top and bottom fabrics are connected by pile warps extending from one to the other of the fabrics, land the length of the pile warp sections between the two grounds, and the consequent length oi.'

the cut pile tufts, may be regulated by mechanically delivering a pre-determined length of such pile warps for each beat of the loom, or the length of the cut pile tufts may be regulated by the use of a set of gaugesv disposed in a substantially horizontal plane between the other two sets of gauges. The latter sets of gauges are shedded by the loom shedding mechanism in weaving, and a double shuttle loom is preferably utilized in weaving the fabrics double so as to lay a pair of wefts simultaneously, but a single shuttle loom Vmay be employed. The pile warps which cross from one ground to the other may be cut either on the loom or subsequently to form the cut pile. In the weaving of my novel fabrics on the double plush principle, a single set of Aground. warps or backing yarns may be used for each vfabric or oppositely acting ground warps may be used as indicated in thedrawing. The ground X warps of each fabric are woven over the wefts thereof oppositely to two sets of pile warps which form uncut loops on the face of the fabric as well as oppositelyto two sets of pile warps which pass .o from one fabric to the other fabric to form out pile tufts on both of them. After every second ground pick in each fabric, a face pick is laid to support a row' .of uncut face pile loops.

The characteristic features and advantages of 55 my method and the product thereof will further appear from the following description and the accompanying drawing in illustration thereof.,

In the drawing, Fig. l is a longitudinalsectional view illustrating diagrammatically the arrangement of yarns and a preferred arrangement of gauges in the weaving of a double fabric in accordance with my invention, and Fig. 2 is a graph illustrating diagrammatically the shedding of warps and top and bottom gauges during the picking of the wefts of a repeat. 10

As shown in the drawing, a double fabric is woven on a double shuttle loom having a set of upper gauge wires A supported at their left hand ends (Fig. l) by the shedding mechanism of the loom, anda set of 'lower gauge wires B supported 15 at their left hand end (Fig. 1) by the shedding mechanism of the loom. A set of stationary gauge wires C may be provided to regulate the distance between the fabrics during weaving and consequently the length of the cut pile. 20

By the utilization of such mechanism and of my improved method, there may be produced a top fabric and a bottom fabric each having a ground and short loops of uncut pile and longer tufts of cut pile. Such fabrics asthey are woven 25 are drawn off the free ends of the gauges A, B and C towards the right (Fig. 1) and are cut apart by severing the pile warps passing from one fabric to the other.

The weaving of the fabric involves the shed- 30 ding of gauges A and of ground warps A'. and A", loop-pile' warps A2, and loop pile warps A3 for the top fabric; the shedding of gauges B, ground warps B and B", loop pile warps B2, and loop pile warps B3 for the bottom fabric; and the 35 shedding of the pile warps C1 and C2 andD1 and D2 for both fabrics. The shuttle or shuttles are so picked and the warps so shedded as to lay a face weft in each fabric and then lay a pair of ground wefts in each fabric, and a repeat in- 40 cludes the laying of twelve pairs of wefts.

At the beginning of the weaving of the fabric fragment shown in Fig.'l (starting at the right of the figure), the shedding mechanisms elevate the warps A', A", B2, A3, D1 and gauges A, de- 45 presses the warps B', B, B3, A2, D2 and gauge B, and holds in intermediate position the warps C and C. This permits the simultaneous or sequential laying ofthe picks la and Ib which are supported respectively against the gauges A and B and support respectively the warps Al and B2 when the latter'are bent to form uncut loops a. on the top fabric and similar loops b on the bottom fabric.

During the beat-up of the picks la and l b the and B2 and ground'warps B' shedding mechanism elevates the warps A2, C', B" and gauges B depresses the warps A', A2, C2 and gauges A and leaves the remaining warps in their former position. The pick 2a may then be laid so that the ground warp A' thereon opposes ground warp A"- and the pile warps A2 A2, C1, and D1. The pick 2b is simultaneously or sequentially laid and the ground warps B' oppose ground warp B" and the pile warps B2, B1, C2 and D2 looped thereunder.

The next movement of the shedding mechanism elevates the ground warps A' and B", loop warps As and B2; depresses the loop warps A2 and A"; moves to intermediate position the cut pile warps C1, C2, D1, D2 and leaves the gauges A and B unchanged. The pick la is then laid so that the ground warp A' opposes the ground warps A" and the pile warps A2 and C1. The pick lbis simultaneously or sequentially laid and the ground warp B' opposes the ground warp B" and the .pile warps B2 and C2.

The shedding mechanism is again operated to elevate the ground warps'A", the loop warps A2, the cut pile warps C1, the gauges A; to depress the backing warps B", the loop warps A2,y the cut pile warps C2 and the gauges B; the position of the remaining warps being unchanged. The weft la when laid is supported against the gauges A and supports the loop warps A11 when these are bent to form the uncut loops a'. The weft 4b is supported against the gauges B and supports the uncut loop b formed by the bending of the warps B2.

The shedding mechanism next lifts the ground warps B1, the loop warps B2, the cut pile warps D2 and the gauges B; depresses the backing warps A', the loop warps B2, the cut pile warps D1 and gauges A, the remaining warps being left as before. The pick or weft 5a is then laid between the ground warps A and the ground warps and the pile warps A2, A2, C1 and D2. Simultaneously or sequentially the pick or weft 5b is laid between the' ground warps B' and the ground warps B" and the pile warps B2, B2, C2 and D1. The engagement of the warps D2 by the pick Ia and the engagement of the warps D1 by the pick 5b causes the pile warps D1 and D2 to cross one another between the fabrics and adjacent to the loops a' and b'.

The next movement of the shedding mechanism elevates the backing warps A', B", the loop warps A2; depresses the backing warps B and A", and the loop warps A2, B2; moves the cut pile warps C1, C2, D1, D2 to intermediate position; the gauges A and B being left unchanged from their previous positions. The weft 6a is then laid in the ground between the ground warps A' and the warps A", A2 and D2. The weft or pick 6b is simultaneously or sequentially laid in the ground of the bottom fabric between the ground warps B' and the warps B", B2 and D1.

This completes half of a cycle, the remainder of which is identical with that described as far as the backing warps and loop pile warps are concerned, but in the second half of the cycle the pile'warps C1 and D1 form w-pile in the bottom fabric instead Iof in the top fabric as in the ilrst half of the cycle, and the pile warps C2 and D2 form w-pile in the top fabric in the second half of the cycle instead of in the bottom fabric as in the first half cycle. The shedding necessary for this will be apparent from Fig. 2 in which the dots indicate that the warp threads or gauges represented thereby are elevated; the crosses indicate that the warp threads represented thereby are in an intermediate position; and the blanks indicate that thevwarp threads or gauges represented thereby are in a depressed position.

Having described my invention, I claim:

In the method of weaving` double fabrics with a set of pile loops gauges for controlling the length of loops on each fabric, the steps which consist in laying aweft above the upper set of gauges and laying a weft below the lower set of gauges, interlacing with the first weft ground warps and a plurality of pile warps; interlacing with the second weft ground warps and a plurality of pile warps; laying a further weft above the upper set of gauges, laying a further weft below the lower set of gauges, interlacing with the third named weft the first named ground warps and a portion only of the first named pile warps; interlacing with the fourth named weft the second named ground warps and a portion only of the second named pile warps; laying a further weft below the upper set of gauges, laying a further weft above the lower set of gauges; interlacing with the fifth named weft warps interlaced with the first named weft which were not interlaced with the third named weft; interlacing with the sixth named weft pile warps interlaced with the second named weft which were not interlaced with the fourth named weft; laying a further weft above the upper set of gauges, laying a further weft below the lower set of gauges; interlacing with the seventh named weft the pile warps interlaced with the fifth named weft and pile warps interlaced with the second 1 named weft; and interlacing with the eighth named weft pile warps interlaced with the sixth named weft and pile warps interlaced with the first named weft.

FRANK M. KAUFMAN. 

